CA2659068A1 - Fiber mat and process of making same - Google Patents
Fiber mat and process of making same Download PDFInfo
- Publication number
- CA2659068A1 CA2659068A1 CA 2659068 CA2659068A CA2659068A1 CA 2659068 A1 CA2659068 A1 CA 2659068A1 CA 2659068 CA2659068 CA 2659068 CA 2659068 A CA2659068 A CA 2659068A CA 2659068 A1 CA2659068 A1 CA 2659068A1
- Authority
- CA
- Canada
- Prior art keywords
- binder
- fiber
- mat
- modifier
- fibers
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000000835 fiber Substances 0.000 title claims abstract description 85
- 238000000034 method Methods 0.000 title abstract description 20
- 239000011230 binding agent Substances 0.000 claims abstract description 56
- 239000003607 modifier Substances 0.000 claims abstract description 25
- BLRPTPMANUNPDV-UHFFFAOYSA-N Silane Chemical compound [SiH4] BLRPTPMANUNPDV-UHFFFAOYSA-N 0.000 claims abstract description 9
- 229910000077 silane Inorganic materials 0.000 claims abstract description 9
- 239000000178 monomer Substances 0.000 claims abstract description 6
- 229920000642 polymer Polymers 0.000 claims abstract description 6
- 239000011248 coating agent Substances 0.000 claims abstract description 3
- 238000000576 coating method Methods 0.000 claims abstract description 3
- 239000003365 glass fiber Substances 0.000 claims description 23
- 239000004566 building material Substances 0.000 claims description 9
- 239000002253 acid Substances 0.000 claims description 7
- 229920005862 polyol Polymers 0.000 claims description 5
- 150000003077 polyols Chemical class 0.000 claims description 5
- NJVOHKFLBKQLIZ-UHFFFAOYSA-N (2-ethenylphenyl) prop-2-enoate Chemical group C=CC(=O)OC1=CC=CC=C1C=C NJVOHKFLBKQLIZ-UHFFFAOYSA-N 0.000 claims description 3
- 239000003431 cross linking reagent Substances 0.000 claims description 3
- 239000000725 suspension Substances 0.000 claims 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 14
- 239000000203 mixture Substances 0.000 description 10
- 239000002002 slurry Substances 0.000 description 10
- 239000002270 dispersing agent Substances 0.000 description 9
- 239000000243 solution Substances 0.000 description 8
- 239000011521 glass Substances 0.000 description 6
- 239000004034 viscosity adjusting agent Substances 0.000 description 6
- 239000006185 dispersion Substances 0.000 description 5
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 4
- -1 but not limited to Substances 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 229920005989 resin Polymers 0.000 description 4
- 239000011347 resin Substances 0.000 description 4
- FZHAPNGMFPVSLP-UHFFFAOYSA-N silanamine Chemical class [SiH3]N FZHAPNGMFPVSLP-UHFFFAOYSA-N 0.000 description 4
- 229920005827 ACRODUR® DS 3558 Polymers 0.000 description 3
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 3
- 239000012736 aqueous medium Substances 0.000 description 3
- 239000007864 aqueous solution Substances 0.000 description 3
- 239000007787 solid Substances 0.000 description 3
- 238000005303 weighing Methods 0.000 description 3
- WYTZZXDRDKSJID-UHFFFAOYSA-N (3-aminopropyl)triethoxysilane Chemical compound CCO[Si](OCC)(OCC)CCCN WYTZZXDRDKSJID-UHFFFAOYSA-N 0.000 description 2
- LVNLBBGBASVLLI-UHFFFAOYSA-N 3-triethoxysilylpropylurea Chemical compound CCO[Si](OCC)(OCC)CCCNC(N)=O LVNLBBGBASVLLI-UHFFFAOYSA-N 0.000 description 2
- XDLMVUHYZWKMMD-UHFFFAOYSA-N 3-trimethoxysilylpropyl 2-methylprop-2-enoate Chemical compound CO[Si](OC)(OC)CCCOC(=O)C(C)=C XDLMVUHYZWKMMD-UHFFFAOYSA-N 0.000 description 2
- NLXLAEXVIDQMFP-UHFFFAOYSA-N Ammonia chloride Chemical compound [NH4+].[Cl-] NLXLAEXVIDQMFP-UHFFFAOYSA-N 0.000 description 2
- KAKZBPTYRLMSJV-UHFFFAOYSA-N Butadiene Chemical compound C=CC=C KAKZBPTYRLMSJV-UHFFFAOYSA-N 0.000 description 2
- 229920000663 Hydroxyethyl cellulose Polymers 0.000 description 2
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 2
- 229910021529 ammonia Inorganic materials 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 239000000839 emulsion Substances 0.000 description 2
- 239000004744 fabric Substances 0.000 description 2
- 239000000945 filler Substances 0.000 description 2
- 239000000834 fixative Substances 0.000 description 2
- 229920001519 homopolymer Polymers 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- 239000004816 latex Substances 0.000 description 2
- 229920000126 latex Polymers 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 239000002609 medium Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 229920002401 polyacrylamide Polymers 0.000 description 2
- 150000004756 silanes Chemical class 0.000 description 2
- 238000005507 spraying Methods 0.000 description 2
- JOXIMZWYDAKGHI-UHFFFAOYSA-N toluene-4-sulfonic acid Chemical compound CC1=CC=C(S(O)(=O)=O)C=C1 JOXIMZWYDAKGHI-UHFFFAOYSA-N 0.000 description 2
- 125000000954 2-hydroxyethyl group Chemical group [H]C([*])([H])C([H])([H])O[H] 0.000 description 1
- MZWXWSVCNSPBLH-UHFFFAOYSA-N 3-(3-aminopropyl-methoxy-methylsilyl)oxypropan-1-amine Chemical compound NCCC[Si](C)(OC)OCCCN MZWXWSVCNSPBLH-UHFFFAOYSA-N 0.000 description 1
- ZYAASQNKCWTPKI-UHFFFAOYSA-N 3-[dimethoxy(methyl)silyl]propan-1-amine Chemical compound CO[Si](C)(OC)CCCN ZYAASQNKCWTPKI-UHFFFAOYSA-N 0.000 description 1
- SJECZPVISLOESU-UHFFFAOYSA-N 3-trimethoxysilylpropan-1-amine Chemical compound CO[Si](OC)(OC)CCCN SJECZPVISLOESU-UHFFFAOYSA-N 0.000 description 1
- SWDDLRSGGCWDPH-UHFFFAOYSA-N 4-triethoxysilylbutan-1-amine Chemical compound CCO[Si](OCC)(OCC)CCCCN SWDDLRSGGCWDPH-UHFFFAOYSA-N 0.000 description 1
- 229920005823 ACRODUR® Polymers 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- PWKSKIMOESPYIA-BYPYZUCNSA-N L-N-acetyl-Cysteine Chemical compound CC(=O)N[C@@H](CS)C(O)=O PWKSKIMOESPYIA-BYPYZUCNSA-N 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004614 Process Aid Substances 0.000 description 1
- 229920004482 WACKER® Polymers 0.000 description 1
- 239000003377 acid catalyst Substances 0.000 description 1
- 238000013019 agitation Methods 0.000 description 1
- 150000001412 amines Chemical class 0.000 description 1
- 235000019270 ammonium chloride Nutrition 0.000 description 1
- 239000010426 asphalt Substances 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 230000003197 catalytic effect Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 239000004035 construction material Substances 0.000 description 1
- 239000013068 control sample Substances 0.000 description 1
- 229920001577 copolymer Polymers 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 238000004132 cross linking Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 125000000524 functional group Chemical group 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- PHQOGHDTIVQXHL-UHFFFAOYSA-N n'-(3-trimethoxysilylpropyl)ethane-1,2-diamine Chemical compound CO[Si](OC)(OC)CCCNCCN PHQOGHDTIVQXHL-UHFFFAOYSA-N 0.000 description 1
- NHBRUUFBSBSTHM-UHFFFAOYSA-N n'-[2-(3-trimethoxysilylpropylamino)ethyl]ethane-1,2-diamine Chemical compound CO[Si](OC)(OC)CCCNCCNCCN NHBRUUFBSBSTHM-UHFFFAOYSA-N 0.000 description 1
- NHLUVTZJQOJKCC-UHFFFAOYSA-N n,n-dimethylhexadecan-1-amine Chemical compound CCCCCCCCCCCCCCCCN(C)C NHLUVTZJQOJKCC-UHFFFAOYSA-N 0.000 description 1
- IBOBFGGLRNWLIL-UHFFFAOYSA-N n,n-dimethylhexadecan-1-amine oxide Chemical compound CCCCCCCCCCCCCCCC[N+](C)(C)[O-] IBOBFGGLRNWLIL-UHFFFAOYSA-N 0.000 description 1
- OZYPPHLDZUUCCI-UHFFFAOYSA-N n-(6-bromopyridin-2-yl)-2,2-dimethylpropanamide Chemical compound CC(C)(C)C(=O)NC1=CC=CC(Br)=N1 OZYPPHLDZUUCCI-UHFFFAOYSA-N 0.000 description 1
- DVYVMJLSUSGYMH-UHFFFAOYSA-N n-methyl-3-trimethoxysilylpropan-1-amine Chemical compound CNCCC[Si](OC)(OC)OC DVYVMJLSUSGYMH-UHFFFAOYSA-N 0.000 description 1
- 230000003472 neutralizing effect Effects 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 229920002239 polyacrylonitrile Polymers 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 239000000523 sample Substances 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 238000009738 saturating Methods 0.000 description 1
- WIJVUKXVPNVPAQ-UHFFFAOYSA-N silyl 2-methylprop-2-enoate Chemical class CC(=C)C(=O)O[SiH3] WIJVUKXVPNVPAQ-UHFFFAOYSA-N 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 229920003048 styrene butadiene rubber Polymers 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- TXDNPSYEJHXKMK-UHFFFAOYSA-N sulfanylsilane Chemical class S[SiH3] TXDNPSYEJHXKMK-UHFFFAOYSA-N 0.000 description 1
- 239000003760 tallow Substances 0.000 description 1
- 150000003512 tertiary amines Chemical class 0.000 description 1
- PZJJKWKADRNWSW-UHFFFAOYSA-N trimethoxysilicon Chemical compound CO[Si](OC)OC PZJJKWKADRNWSW-UHFFFAOYSA-N 0.000 description 1
- 238000009827 uniform distribution Methods 0.000 description 1
- UKRDPEFKFJNXQM-UHFFFAOYSA-N vinylsilane Chemical class [SiH3]C=C UKRDPEFKFJNXQM-UHFFFAOYSA-N 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Classifications
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
- D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
- D04H1/587—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives characterised by the bonding agents used
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/54—Silicon-containing compounds
- C08K5/544—Silicon-containing compounds containing nitrogen
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
- Y10T442/2926—Coated or impregnated inorganic fiber fabric
- Y10T442/2992—Coated or impregnated glass fiber fabric
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Dispersion Chemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
- Nonwoven Fabrics (AREA)
- Paper (AREA)
Abstract
A fiber mat of improved hot wet tensile strength and a process of making same is disclosed. The fiber mat consists of fibers; a formaldehyde- free resinous fiber binder coating the fibers; and a binder-modifier which is a functional silane monomer or polymer.
Description
~
FIBER MAT AND PROCESS OF MAKING SAME
BACKGROUND OF THE INVENTION
Field of the Invention The present invention relates generally to a fiber mat and a process of making the same, and, more particularly, to a glass fiber mat comprising fibers, a formaldehyde-free binder and a defined binder modifier. Embodiments of the present invention can have desired characteristics, such as, for example, improved hot wet tensile strength, as compared with a conventional mat where no such defined binder modifier is employed, and can be suitable for use in building materials.
Description of the Prior Art High strength fiber mats have become increasingly popular in the building materials industry. Most commonly used in roofing shingles, fiber mats have numerous other material applications, including use in roofing, siding and floor underlayment; insulation facers; floor and ceiling tile; and vehicle parts.
Various fiber mats and methods of making same have been previously described utilizing formaldehyde-free binders. For example, U.S. Patent Nos.
5,932,665, 6,114,464, 6,299,936, 6,136,916, 6,348,530, 4,135,029 and 6,642,299;
and EP 1655400A1 and WO 20061009823 A2; describe glass fiber mats made by a wet-laid process. Glass fiber mats made by the wet-laid process are formed from glass fibers held together by a binder material. Typically, in wet process glass fiber mats, the binder is applied in a liquid form and dispersed onto the glass fibers by a curtain type applicator. Conventional wet processes strive to produce a uniform coating of binder on the glass fibers. After the binder and glass fibers have been dried and cured, the glass fiber mat is then cut as desired.
A major problem in the manufacture and use of some known fiber mats is inadequate hot wet tensile strength. Inadequate hot wet tensile strength can cause interruption in roofing manufacture, and may reduce the ability of the finished roofing product to resist stresses during service on the roof. Because building materials, generally, and roofing shingles, in particular, are often subjected to a variety of weather conditions, the fiber mats must also maintain their strength characteristics under a wide range of conditions.
Similarly, high temperatures can affect shingle performance. The tensile strength over these temperature ranges may depend on the adhesion of the fibers to the fiber binder system, the mechanical properties of the binder system, and the interaction of the fiber mats with asphalt.
Various embodiments of the present invention may be suitable for use as a component of building materials, and other applications. Various embodiments may provide a material having improved tensile strength under a variety of conditions. In addition, the process of making fiber mats in accordance with some embodiments of the present invention may provide a fiber mat having improved hot wet tensile strength. Additional advantages of embodiments of the invention are set forth, in part, in the description which follows and, in part, will be apparent to one of ordinary skill in the art from the description andlor from the practice of the invention.
SUMMARY OF THE INVENTION
Responsive to the foregoing challenges, Applicants have developed an innovative fiber mat for use in a building material, the mat comprising:
about 55% w/w to 99.5% w/w, and preferably 72% w/w to 98% w/w of fibers;
and about 0.05 % w/w to 45% w/w, and preferably 2% w/w to 28% w/w of a formaldehyde-free binder which coats the fibers, and 0.1 % w/w to 20% wlw, and preferably 0.5% w/w to 10% w/w, of a binder modifier which is a functional silane monomer or polymer, based on the weight of the binder, or the binder to the functional silane is about 1000:1 to 4:1, and, preferably, about 200:1 to 9:1.
Applicants have developed an innovative process of making a fiber mat for use in a building material, the process comprising the steps of: (a) forming an aqueous fiber slurry; (b) removing water from the fiber slurry to form a wet fiber mat ;
(c) saturating the wet fiber mat with an aqueous solution of a fiber binder;
(d) spraying the wet fiber mat with a binder modifier and (e) drying and curing the wet fiber mat to form a fiber mat product. In one embodiment, the fiber binder and the binder modifier may be mixed together and applied in a single step.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only, and are not restrictive of the invention as claimed.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
ln suitable embodiments of the present invention the formafdehyde-free binder is ACRODUR DS-3558 resin binder (styrene-acrylate dispersion modified with polycarboxylic acid and a polyol as the crosslinking agent) supplied by BASF
was used. The individual glass fiber parts were soaked in the binder solution under ambient conditions after which excess solution was removed under vacuum to provide binder wet mats containing about 6-62%% w/w fibers, 8-10% w/w binder, and about 30% w/w water.
The fiber binder may comprise between about 5 wt.% and about 30 wt.%, based on the fiber mat product weight.
The functional silane monomer or polymer which is the binder modifier of the invention contains a functional group which can couple with the resinous fiber binder material, Suitable functional silanes include amino silanes, vinyl silanes, methacryloxy silanes, mercaptosilanes, and epoxy silanes.
Examples of such functional silane monomers and polymers thereof, include gamma-aminopropyltrialkoxysilanes, gamma-isocyanatopropyl-triethoxysilane, vinyl-trialkoxysilanes, glycidoxypropyltrialkoxysilanes and ureidopropyltrialkoxysilanes, such as A-187 gamma-glycidoxy-propyitrimethoxysilanes, A-174 gamma-methacryloxypropyltrimethoxysilane, A-1100 gamma-aminopropyl-triethoxysilane, A-1108 amino silane and A-1160 gamma-ureidopropyl-triethoxysilane (each of which are commercially available from OSi Specialties, Inc. of Tarrytown, N.Y.).
FIBER MAT AND PROCESS OF MAKING SAME
BACKGROUND OF THE INVENTION
Field of the Invention The present invention relates generally to a fiber mat and a process of making the same, and, more particularly, to a glass fiber mat comprising fibers, a formaldehyde-free binder and a defined binder modifier. Embodiments of the present invention can have desired characteristics, such as, for example, improved hot wet tensile strength, as compared with a conventional mat where no such defined binder modifier is employed, and can be suitable for use in building materials.
Description of the Prior Art High strength fiber mats have become increasingly popular in the building materials industry. Most commonly used in roofing shingles, fiber mats have numerous other material applications, including use in roofing, siding and floor underlayment; insulation facers; floor and ceiling tile; and vehicle parts.
Various fiber mats and methods of making same have been previously described utilizing formaldehyde-free binders. For example, U.S. Patent Nos.
5,932,665, 6,114,464, 6,299,936, 6,136,916, 6,348,530, 4,135,029 and 6,642,299;
and EP 1655400A1 and WO 20061009823 A2; describe glass fiber mats made by a wet-laid process. Glass fiber mats made by the wet-laid process are formed from glass fibers held together by a binder material. Typically, in wet process glass fiber mats, the binder is applied in a liquid form and dispersed onto the glass fibers by a curtain type applicator. Conventional wet processes strive to produce a uniform coating of binder on the glass fibers. After the binder and glass fibers have been dried and cured, the glass fiber mat is then cut as desired.
A major problem in the manufacture and use of some known fiber mats is inadequate hot wet tensile strength. Inadequate hot wet tensile strength can cause interruption in roofing manufacture, and may reduce the ability of the finished roofing product to resist stresses during service on the roof. Because building materials, generally, and roofing shingles, in particular, are often subjected to a variety of weather conditions, the fiber mats must also maintain their strength characteristics under a wide range of conditions.
Similarly, high temperatures can affect shingle performance. The tensile strength over these temperature ranges may depend on the adhesion of the fibers to the fiber binder system, the mechanical properties of the binder system, and the interaction of the fiber mats with asphalt.
Various embodiments of the present invention may be suitable for use as a component of building materials, and other applications. Various embodiments may provide a material having improved tensile strength under a variety of conditions. In addition, the process of making fiber mats in accordance with some embodiments of the present invention may provide a fiber mat having improved hot wet tensile strength. Additional advantages of embodiments of the invention are set forth, in part, in the description which follows and, in part, will be apparent to one of ordinary skill in the art from the description andlor from the practice of the invention.
SUMMARY OF THE INVENTION
Responsive to the foregoing challenges, Applicants have developed an innovative fiber mat for use in a building material, the mat comprising:
about 55% w/w to 99.5% w/w, and preferably 72% w/w to 98% w/w of fibers;
and about 0.05 % w/w to 45% w/w, and preferably 2% w/w to 28% w/w of a formaldehyde-free binder which coats the fibers, and 0.1 % w/w to 20% wlw, and preferably 0.5% w/w to 10% w/w, of a binder modifier which is a functional silane monomer or polymer, based on the weight of the binder, or the binder to the functional silane is about 1000:1 to 4:1, and, preferably, about 200:1 to 9:1.
Applicants have developed an innovative process of making a fiber mat for use in a building material, the process comprising the steps of: (a) forming an aqueous fiber slurry; (b) removing water from the fiber slurry to form a wet fiber mat ;
(c) saturating the wet fiber mat with an aqueous solution of a fiber binder;
(d) spraying the wet fiber mat with a binder modifier and (e) drying and curing the wet fiber mat to form a fiber mat product. In one embodiment, the fiber binder and the binder modifier may be mixed together and applied in a single step.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only, and are not restrictive of the invention as claimed.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
ln suitable embodiments of the present invention the formafdehyde-free binder is ACRODUR DS-3558 resin binder (styrene-acrylate dispersion modified with polycarboxylic acid and a polyol as the crosslinking agent) supplied by BASF
was used. The individual glass fiber parts were soaked in the binder solution under ambient conditions after which excess solution was removed under vacuum to provide binder wet mats containing about 6-62%% w/w fibers, 8-10% w/w binder, and about 30% w/w water.
The fiber binder may comprise between about 5 wt.% and about 30 wt.%, based on the fiber mat product weight.
The functional silane monomer or polymer which is the binder modifier of the invention contains a functional group which can couple with the resinous fiber binder material, Suitable functional silanes include amino silanes, vinyl silanes, methacryloxy silanes, mercaptosilanes, and epoxy silanes.
Examples of such functional silane monomers and polymers thereof, include gamma-aminopropyltrialkoxysilanes, gamma-isocyanatopropyl-triethoxysilane, vinyl-trialkoxysilanes, glycidoxypropyltrialkoxysilanes and ureidopropyltrialkoxysilanes, such as A-187 gamma-glycidoxy-propyitrimethoxysilanes, A-174 gamma-methacryloxypropyltrimethoxysilane, A-1100 gamma-aminopropyl-triethoxysilane, A-1108 amino silane and A-1160 gamma-ureidopropyl-triethoxysilane (each of which are commercially available from OSi Specialties, Inc. of Tarrytown, N.Y.).
Amino silane, monomers and polymers have been found to be particularly effective binder modifiers, e.g. trimethoxysilylpropyldiethylene- triamine, N-methylaminopropy[trimethoxysilane, aminoethylaminopropylmethyldimethoxysilane, aminoethylaminopropyltrimethoxysiiane (Dow Corning Z-6020), a homopolymer of an amino silane (Dow Corning Z-6137), aminopropylmethyldimethoxysilane, aminopropyltrimethoxysilane, polymeric aminoalkylsilicone, aminoethylaminoethylaminopropyl-trimethoxysi[ane, N-methylaminopropyltrimethoxysilane, methylamino-propyftrimethoxysilane, aminopropyfinethyldimethoxysilane, aminopropyltriethoxysilane, 4-aminobutyltriethoxysilane, and oligomeric aminoalkylsilane and the like, which are available from Dow Corning, Midland, Mich., Union Carbide Specialty Chemicals Division, Danbury Connecticut and Huls of America, Piscataway, N.J., Wacker Silicones Corporation of Adrian, Mich.
The formaldehyde-free fiber binder and the binder modifier are adapted to be compatible. The components may be intimately admixed in an aqueous medium to form a stable emulsion which may not become overly gummy, or gel, even after storage for periods of 24 hours or longer. This may be advantageous in practical commercial use of the composition. It is contemplated that individual aqueous mixtures for binder and modifier may be used in embodiments of the present invention.
In one embodiment of the present invention, the fibers comprise glass fibers.
The glass fibers may comprise individual fiber filaments having an average length in the range of, but not limited to, from about'/ inch to about 3 inches, and an average diameter in the range of, but not limited to, from about 5 to about 50 micrometers (pm). It is contemplated, however, that the glass fibers may be in another form, such as, for example, a continuous strand or strands. In an alternative embodiment of the present invention, the fibers may comprise other fibers, including, but not limited to, wood, polyethylene, polyester, nylon, polyacrylonitrile, and/or a mixture of glass and one or more other fibers. In one embodiment, the fiber mat may further comprise a small amount of filler, e.g. less than about 0.5%, based on the fiber weight. A fiber mixture may be optional for construction material application, such as, for example, roofing and siding, because excessive amounts of filler may reduce porosity and vapor ventability of the fiber mat.
In the finished cured mat product, the fiber content may be in the range of 5 from about 55 wt.% to about 98 wt.%. In one embodiment of the present invention, the fiber content is more particularly in the range of from about 66 wt.% and about 88 wt.%. The binder content may be in the range of from about 0.05 wt. % to about 45 wt. %. In one embodiment of the present invention, the binder content is more particularly in the range of from about 15 wt. % to about 30 wt. %.
In one embodiment of the present invention, the fibers may be formed into a mat with the aid of a dispersing agent. The fiber dispersing agent may comprise, for example, tertiary amine oxides (e.g. N-hexadecyl-N,N-dimethyl amine oxide), bis(2-hydroxyethyl) tallow amine oxide, dimethyl hydrogenated tallow amine oxide, dimethylstearyl amine oxide and the like, and/or mixtures thereof. As will be apparent to those of ordinary skill in the art, other known dispersing agents may be used without departing from the scope and spirit of the present invention. The dispersing agent may comprise a concentration in the range of from about 10 ppm to about 8,000 ppm, based on the amount of fiber. The dispersing agent may further comprise a concentration in the range of from about 200 ppm to about 1,000 ppm, based on the amount of fiber.
In one embodiment, the fibers may be formed into a mat with the aid of one or more viscosity modifiers. The viscosity modifier may be adapted to increase the viscosity of the composition such that the settling time of the fibers is reduced and the fibers may be adequately dispersed. The viscosity modifier may include, but is not limited to, hydroxyl ethyl cellulose (HEC), polyacrylamide (PAA), and the like. As will be apparent to those of ordinary skill in the art, other viscosity modifiers may be used without departing from the scope and spirit of the present invention.
The process of making a fiber mat in accordance with one embodiment of the present invention will now be described. The process will be described with particular reference to a wet-laid process. It is contemplated, however, that other processes known in the art, such as, for example, a dry-laid process, may be used without departing from the scope and spirit of the present invention.
Furthermore, the process is described using chopped bundles of glass fibers. As discussed above, however, other types of fiber content are considered well within the scope of the present invention.
The process of forming glass fiber mats according to one embodiment of the present invention comprises adding chopped bundles of glass fibers of suitable length and diameter to an aqueous medium to form an aqueous fiber slurry. As discussed above, the aqueous medium may include a suitable dispersing agent. A
viscosity modifier or other process aid may also be added to the water/dispersing agent medium. From about 0.05 to about 0.5 wt.% viscosity modifier in white water may be suitably added to the dispersant to form the slurry.
The glass fibers may be sized or unsized, and may be wet or dry, as long as they are capable of being suitably dispersed in the water/dispersing agent medium.
The fiber slurry, containing from about 0.03 wt. % to about 8 wt. % solids, is then agitated to form a workable dispersion at a suitable and uniform consistency.
The fiber slurry may be additionally diluted with water to a lower fiber concentration to between about 0.02 wt. % and about 0.08 wt. %. In one embodiment, the fiber concentration may be more particularly diluted to about 0.04 wt. % fiber. The fiber slurry is then passed to a mat-forming machine such as a wire screen or fabric for drainage of excess water. The excess water may be removed with the assistance of vacuum.
The fibers of the slurry are deposited on the wire screen and drained to form a fiber mat. The fiber mat may then be saturated with an aqueous solution of binder. The aqueous binder solution may comprise, for example, from about 10 wt.% to about 40 wt.% solids. The fiber mat may be soaked for a period of time sufficient to provide the desired fixative for the fibers. Excess aqueous binder solution may then be removed, preferably under vacuum.
The formed fiber mat may then be sprayed with the binder modifier to achieve the desired concentration. An aqueous solution of the modifier may be used to obtain a uniform distribution over the binder treated fibers. In one embodiment of the present invention, either before or after applying the binder modifier, the fiber mat may be compressed, for example by passing it between rollers or another compressing device, to reduce mat thickness for curing. In addition to spraying, this invention also contemplates neutralizing the acid with a base such as ammonia and adding it into binder solution to avoid gelling. It is believed that the ammonia will volatize at high curing temperature and the acid form will return.
After treatment with binder and binder-modifier composition, the mat is then dried and the fixative composition may be cured in an oven at an elevated temperature. A temperature in the range of about 160 C to about 400 C, for at least about 2 seconds, may be used for curing. In one embodiment, a cure temperature in the range of about 225 C to about 350 C may be used. It is contemplated that in an alternative embodiment of the present invention, catalytic curing may be provided with an acid catalyst, such as, for example, ammonium chloride, p-toluene sulfonic acid, or any other suitable catalyst.
The combination of the modified emulsion and binder used in various embodiments of the present invention may provide several advantages over current binder compositions. For example, the tensile strength of the mat may be increased. In addition, the tensile strength of the mat may be increased at lower temperatures to minimize cracking and failure. Other advantages will be apparent to one of ordinary skill in the art from the above detailed description and/or from the practice of the invention.
Having generally described various embodiments of the present invention, reference is now made to the following example which illustrates embodiments of the present invention and comparisons to a control sample. The following examples serve to illustrate, but are not to be construed as limiting to, the scope of the invention as set forth in the appended claims.
The formaldehyde-free fiber binder and the binder modifier are adapted to be compatible. The components may be intimately admixed in an aqueous medium to form a stable emulsion which may not become overly gummy, or gel, even after storage for periods of 24 hours or longer. This may be advantageous in practical commercial use of the composition. It is contemplated that individual aqueous mixtures for binder and modifier may be used in embodiments of the present invention.
In one embodiment of the present invention, the fibers comprise glass fibers.
The glass fibers may comprise individual fiber filaments having an average length in the range of, but not limited to, from about'/ inch to about 3 inches, and an average diameter in the range of, but not limited to, from about 5 to about 50 micrometers (pm). It is contemplated, however, that the glass fibers may be in another form, such as, for example, a continuous strand or strands. In an alternative embodiment of the present invention, the fibers may comprise other fibers, including, but not limited to, wood, polyethylene, polyester, nylon, polyacrylonitrile, and/or a mixture of glass and one or more other fibers. In one embodiment, the fiber mat may further comprise a small amount of filler, e.g. less than about 0.5%, based on the fiber weight. A fiber mixture may be optional for construction material application, such as, for example, roofing and siding, because excessive amounts of filler may reduce porosity and vapor ventability of the fiber mat.
In the finished cured mat product, the fiber content may be in the range of 5 from about 55 wt.% to about 98 wt.%. In one embodiment of the present invention, the fiber content is more particularly in the range of from about 66 wt.% and about 88 wt.%. The binder content may be in the range of from about 0.05 wt. % to about 45 wt. %. In one embodiment of the present invention, the binder content is more particularly in the range of from about 15 wt. % to about 30 wt. %.
In one embodiment of the present invention, the fibers may be formed into a mat with the aid of a dispersing agent. The fiber dispersing agent may comprise, for example, tertiary amine oxides (e.g. N-hexadecyl-N,N-dimethyl amine oxide), bis(2-hydroxyethyl) tallow amine oxide, dimethyl hydrogenated tallow amine oxide, dimethylstearyl amine oxide and the like, and/or mixtures thereof. As will be apparent to those of ordinary skill in the art, other known dispersing agents may be used without departing from the scope and spirit of the present invention. The dispersing agent may comprise a concentration in the range of from about 10 ppm to about 8,000 ppm, based on the amount of fiber. The dispersing agent may further comprise a concentration in the range of from about 200 ppm to about 1,000 ppm, based on the amount of fiber.
In one embodiment, the fibers may be formed into a mat with the aid of one or more viscosity modifiers. The viscosity modifier may be adapted to increase the viscosity of the composition such that the settling time of the fibers is reduced and the fibers may be adequately dispersed. The viscosity modifier may include, but is not limited to, hydroxyl ethyl cellulose (HEC), polyacrylamide (PAA), and the like. As will be apparent to those of ordinary skill in the art, other viscosity modifiers may be used without departing from the scope and spirit of the present invention.
The process of making a fiber mat in accordance with one embodiment of the present invention will now be described. The process will be described with particular reference to a wet-laid process. It is contemplated, however, that other processes known in the art, such as, for example, a dry-laid process, may be used without departing from the scope and spirit of the present invention.
Furthermore, the process is described using chopped bundles of glass fibers. As discussed above, however, other types of fiber content are considered well within the scope of the present invention.
The process of forming glass fiber mats according to one embodiment of the present invention comprises adding chopped bundles of glass fibers of suitable length and diameter to an aqueous medium to form an aqueous fiber slurry. As discussed above, the aqueous medium may include a suitable dispersing agent. A
viscosity modifier or other process aid may also be added to the water/dispersing agent medium. From about 0.05 to about 0.5 wt.% viscosity modifier in white water may be suitably added to the dispersant to form the slurry.
The glass fibers may be sized or unsized, and may be wet or dry, as long as they are capable of being suitably dispersed in the water/dispersing agent medium.
The fiber slurry, containing from about 0.03 wt. % to about 8 wt. % solids, is then agitated to form a workable dispersion at a suitable and uniform consistency.
The fiber slurry may be additionally diluted with water to a lower fiber concentration to between about 0.02 wt. % and about 0.08 wt. %. In one embodiment, the fiber concentration may be more particularly diluted to about 0.04 wt. % fiber. The fiber slurry is then passed to a mat-forming machine such as a wire screen or fabric for drainage of excess water. The excess water may be removed with the assistance of vacuum.
The fibers of the slurry are deposited on the wire screen and drained to form a fiber mat. The fiber mat may then be saturated with an aqueous solution of binder. The aqueous binder solution may comprise, for example, from about 10 wt.% to about 40 wt.% solids. The fiber mat may be soaked for a period of time sufficient to provide the desired fixative for the fibers. Excess aqueous binder solution may then be removed, preferably under vacuum.
The formed fiber mat may then be sprayed with the binder modifier to achieve the desired concentration. An aqueous solution of the modifier may be used to obtain a uniform distribution over the binder treated fibers. In one embodiment of the present invention, either before or after applying the binder modifier, the fiber mat may be compressed, for example by passing it between rollers or another compressing device, to reduce mat thickness for curing. In addition to spraying, this invention also contemplates neutralizing the acid with a base such as ammonia and adding it into binder solution to avoid gelling. It is believed that the ammonia will volatize at high curing temperature and the acid form will return.
After treatment with binder and binder-modifier composition, the mat is then dried and the fixative composition may be cured in an oven at an elevated temperature. A temperature in the range of about 160 C to about 400 C, for at least about 2 seconds, may be used for curing. In one embodiment, a cure temperature in the range of about 225 C to about 350 C may be used. It is contemplated that in an alternative embodiment of the present invention, catalytic curing may be provided with an acid catalyst, such as, for example, ammonium chloride, p-toluene sulfonic acid, or any other suitable catalyst.
The combination of the modified emulsion and binder used in various embodiments of the present invention may provide several advantages over current binder compositions. For example, the tensile strength of the mat may be increased. In addition, the tensile strength of the mat may be increased at lower temperatures to minimize cracking and failure. Other advantages will be apparent to one of ordinary skill in the art from the above detailed description and/or from the practice of the invention.
Having generally described various embodiments of the present invention, reference is now made to the following example which illustrates embodiments of the present invention and comparisons to a control sample. The following examples serve to illustrate, but are not to be construed as limiting to, the scope of the invention as set forth in the appended claims.
Preparation of Glass Mat Part A. In a 20 liter vessel at room temperature, under constant agitation, 5.50 g of chopped bundles of glass fibers, having an average 20-40 mm length and 12-20 micron diameter, were dispersed in 12 liters of water containing 800 ppm of N-hexadecyl-N,N-dimethylamine oxide to produce a uniform aqueous slurry of 0.04 wt.% fibers. The fiber slurry was then passed onto a wire mesh support with dewatering fabric, and a vacuum was applied to remove excess water and to obtain a wet mat containing about 60% fibers.
Part B. Aqueous samples of 10 wt.% solids containing ACRODUR DS-3558 resin binder (styrene-acrylate dispersion modified with polycarboxylic acid and a polyol as the X-linking agent) supplied by BASF and a binder modifier which was Dow Corning Z-69 37 Silane supplied by Dow Corning Corp. was prepared and applied to individual samples of wet glass mats prepared by the procedure in Part A. The individual wet glass mats were soaked in the binder/modifier solution under ambient conditions after which excess solution was removed under vacuum to provide binder wet mats containing 63 wt. /fl glass fibers, 7 wt. /a binder and 30 wt.%
water.
Part C. For comparison purposes, Control samples were prepared as described in Parts A and B except that the UF binder, HexionFG607A, supplied by Hexion Specialty Chemcials, was used alone or with OmnovaGenflo3112 latex, i.e. a carboxylated styrene-butadiene copolymer latex supplied by Omnova Solutions Inc.
Part D. For comparison purposes, Control-B samples were prepared as described in Parts A and B except that formaldehyde-free resin, ACRODUR DS-3558 was used without the addition of Dow Corning's Z6137 Silane binder-modifier.
Part E. The mat samples made according to Parts A and B were dried and cured for 8 seconds at 225 C to obtain dry glass mats weighing about 79 g/m2 and having a Loss on Ignition (LOI) of about 10%.
Part F. The mat samples made according to Part C were dried and cured for 8 seconds at 285 C to obtain dry glass mats weighing about 92 g/m2 and having a Loss on Ignition (LOl) of about 19%.
Part B. Aqueous samples of 10 wt.% solids containing ACRODUR DS-3558 resin binder (styrene-acrylate dispersion modified with polycarboxylic acid and a polyol as the X-linking agent) supplied by BASF and a binder modifier which was Dow Corning Z-69 37 Silane supplied by Dow Corning Corp. was prepared and applied to individual samples of wet glass mats prepared by the procedure in Part A. The individual wet glass mats were soaked in the binder/modifier solution under ambient conditions after which excess solution was removed under vacuum to provide binder wet mats containing 63 wt. /fl glass fibers, 7 wt. /a binder and 30 wt.%
water.
Part C. For comparison purposes, Control samples were prepared as described in Parts A and B except that the UF binder, HexionFG607A, supplied by Hexion Specialty Chemcials, was used alone or with OmnovaGenflo3112 latex, i.e. a carboxylated styrene-butadiene copolymer latex supplied by Omnova Solutions Inc.
Part D. For comparison purposes, Control-B samples were prepared as described in Parts A and B except that formaldehyde-free resin, ACRODUR DS-3558 was used without the addition of Dow Corning's Z6137 Silane binder-modifier.
Part E. The mat samples made according to Parts A and B were dried and cured for 8 seconds at 225 C to obtain dry glass mats weighing about 79 g/m2 and having a Loss on Ignition (LOI) of about 10%.
Part F. The mat samples made according to Part C were dried and cured for 8 seconds at 285 C to obtain dry glass mats weighing about 92 g/m2 and having a Loss on Ignition (LOl) of about 19%.
Part G. The mat samples made according to Parts A and D were dried and cured for 8 seconds at 225 C to obtain dry glass mats weighing about 89 g/m2 and having a Loss on Ignition (LO!) of about 9%.
Part H. After the cure, the mat hot wet tensile strength was measured in the following way. The 50 mm x 200 mm cured mat strip was soaked in a 80 C water bath for 10 minutes, then blotting paper was used to remove the excess water on the wet mat strip. The wet tensile of the mat strip was measured on an Instron Tensile Tester. The percent of hot wet tensile retention was determined by dividing the wet tensile by the dry tensile of the mat sample that was not soaked in the water bath. % Hot Wet Tensile = (Wet Tensile Average/Dry Tensile Average) x 100.
The results of these tests are given in the Tables 1 and 2 below.
Binder Compositions Ingredient Control-A Control-B Invention Example Binder Hexion FG607A ACRODUR DS- ACRODURR
Binder Urea- Styrene-acrylate Styrene-acrylate Chemistry Formaldehyde dispersion dispersion Resin modified with modified with polycarboxylic polycarboxylic acid and a polyol acid and a as the polyol as the crosslinking crosslinking agent agent Modifier Omnova N/A Dow Corning Genflo31 12 Z6137 Modifier Carboxylated N/A Homopolymer of Chemistry Styrene an Butadiene Aminofunctional Copolymer Silane Binder/Modifier 99/1 100/0 99.5/0.5 (w/w) Mat Properties Property Control- Control- Invention Changed %
A B Example over Control Mat Basis 92 89 79 Weight (gms) Mat LOi% 19 9 10 ---Curing 285C/8 225C/8 225C18 ---sec sec sec % Hot Wet Mat 61 59 99 -r65 Tensile 5 The results show a significant increase in % Hot Wet Mat Tensile Strength for the Invention Example over Control samples.
It will be apparent to those skilled in the art that various other modifications and variations can be made in the construction, configuration, and/or operation of the present invention without departing from the scope or spirit of the invention.
Part H. After the cure, the mat hot wet tensile strength was measured in the following way. The 50 mm x 200 mm cured mat strip was soaked in a 80 C water bath for 10 minutes, then blotting paper was used to remove the excess water on the wet mat strip. The wet tensile of the mat strip was measured on an Instron Tensile Tester. The percent of hot wet tensile retention was determined by dividing the wet tensile by the dry tensile of the mat sample that was not soaked in the water bath. % Hot Wet Tensile = (Wet Tensile Average/Dry Tensile Average) x 100.
The results of these tests are given in the Tables 1 and 2 below.
Binder Compositions Ingredient Control-A Control-B Invention Example Binder Hexion FG607A ACRODUR DS- ACRODURR
Binder Urea- Styrene-acrylate Styrene-acrylate Chemistry Formaldehyde dispersion dispersion Resin modified with modified with polycarboxylic polycarboxylic acid and a polyol acid and a as the polyol as the crosslinking crosslinking agent agent Modifier Omnova N/A Dow Corning Genflo31 12 Z6137 Modifier Carboxylated N/A Homopolymer of Chemistry Styrene an Butadiene Aminofunctional Copolymer Silane Binder/Modifier 99/1 100/0 99.5/0.5 (w/w) Mat Properties Property Control- Control- Invention Changed %
A B Example over Control Mat Basis 92 89 79 Weight (gms) Mat LOi% 19 9 10 ---Curing 285C/8 225C/8 225C18 ---sec sec sec % Hot Wet Mat 61 59 99 -r65 Tensile 5 The results show a significant increase in % Hot Wet Mat Tensile Strength for the Invention Example over Control samples.
It will be apparent to those skilled in the art that various other modifications and variations can be made in the construction, configuration, and/or operation of the present invention without departing from the scope or spirit of the invention.
10 Embodiments of the fiber mat may be used in the building material including but not limited to, shingles, underlayment, insulation facers, floor and ceiling tile, vehicle parts, and/or any other suitable building material. Thus, it is intended that that present invention cover all such modifications and variations of the invention, provided they come within the scope of the appended claims and their equivalents.
Claims (6)
1. A formaldehyde-free fiber mat for use in a building material, said fiber mat comprising:
55% w/w to 99.5% w/w of a plurality of fibers; and 0.05 % w/w to 45% w/w of a formaldehyde-free resinous binder coating said fibers, and a fiber binder-modifier wherein said fiber binder-modifier is a functional silane monomer or polymer, wherein the wt. ratio of binder:modifier is 1000:1 to 4:1.
55% w/w to 99.5% w/w of a plurality of fibers; and 0.05 % w/w to 45% w/w of a formaldehyde-free resinous binder coating said fibers, and a fiber binder-modifier wherein said fiber binder-modifier is a functional silane monomer or polymer, wherein the wt. ratio of binder:modifier is 1000:1 to 4:1.
2. The fiber mat of Claim 1 wherein said fiber binder:modifier wt.
ratio is about 200:1 to 9:1.
ratio is about 200:1 to 9:1.
3. A formaldehyde-free glass fiber mat according to claim wherein said fiber binder-modifier is an aminofunctional silane.
4. The glass fiber mat of Claim 3 wherein the concentration of said fibers is 55% to about 98% w/w.
5. The glass fiber mat of Claim 4 having increased hot wet mat tensile strength.
6. The glass fiber mat of Claim 1 wherein said binder is a styrene-acrylate suspension modified with polycarboxylic acid and a polyol as the cross-linking agent.
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US11/485,197 | 2006-07-12 | ||
US11/485,197 US20070059508A1 (en) | 2005-09-13 | 2006-07-12 | Fiber mat and process of making same |
PCT/US2007/073316 WO2008008868A2 (en) | 2006-07-12 | 2007-07-12 | Fiber mat |
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CA2659068A1 true CA2659068A1 (en) | 2008-01-17 |
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US (2) | US20070059508A1 (en) |
CA (1) | CA2659068A1 (en) |
MX (1) | MX2008015438A (en) |
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JP4154727B2 (en) * | 2003-04-22 | 2008-09-24 | 王子製紙株式会社 | Wet method nonwoven fabric and method for producing the same |
CA2734137C (en) * | 2010-03-05 | 2015-08-11 | Basf Se | Styrene-butadiene-based binders and methods of preparing and using same |
EP2616230B1 (en) | 2010-09-15 | 2017-12-13 | Jeld-Wen, Inc. | Method and system for forming a thin-layer moisture-resistant fiber composite material |
PL2843129T5 (en) * | 2013-08-30 | 2023-09-18 | Saint-Gobain Placo | Reinforced gypsum board having improved fire resistance |
EP3530804B1 (en) | 2018-02-27 | 2023-09-06 | Synthomer Deutschland GmbH | Latex bonded textile fiber structure for construction applications |
GB201911659D0 (en) | 2019-08-15 | 2019-10-02 | Synthomer Deutschland Gmbh | Latex for bonding fiber structures |
CA3157370A1 (en) * | 2019-10-28 | 2021-05-06 | Owens Corning Intellectual Capital, Llc | Cross-linked non-woven mat |
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Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3253948A (en) * | 1962-02-12 | 1966-05-31 | Owens Corning Fiberglass Corp | Glass fiber product |
US3616179A (en) * | 1968-01-18 | 1971-10-26 | Owens Corning Fiberglass Corp | Glass fiber product bonded with terpolymer comprising phenol formaldehyde-urea formaldehyde condensation product |
FR2223318B1 (en) * | 1973-03-30 | 1978-03-03 | Saint Gobain | |
GB1577561A (en) * | 1976-04-29 | 1980-10-29 | Cons Fiberglass Prod | Fibreglass mat |
US4650889A (en) * | 1985-11-29 | 1987-03-17 | Dow Corning Corporation | Silane coupling agents |
DE3727181A1 (en) * | 1987-08-14 | 1989-02-23 | Wacker Chemie Gmbh | USE OF SELF-CROSS-LINKED VINYLESTER DISPERSIONS WITH REDUCED RELATIONSHIPS WITHOUT FORMALDEHYDE CONTENT FOR STRENGTHENING TEXTILE FIBER FABRICS |
US5178657A (en) * | 1988-10-27 | 1993-01-12 | Saint-Gobain Recherche | Binder and binder-based size for mineral fibers |
US5661213A (en) * | 1992-08-06 | 1997-08-26 | Rohm And Haas Company | Curable aqueous composition and use as fiberglass nonwoven binder |
PT1038910E (en) * | 1995-08-11 | 2004-11-30 | Henkel Kgaa | COLOFONIUM RESINS SOLUTIONS |
DE19621573A1 (en) * | 1996-05-29 | 1997-12-04 | Basf Ag | Thermally curable, aqueous compositions |
US5932665A (en) * | 1997-02-06 | 1999-08-03 | Johns Manville International, Inc. | Polycarboxy polymer acid binders having reduced cure temperatures |
DE19729161A1 (en) * | 1997-07-08 | 1999-01-14 | Basf Ag | Thermally curable, aqueous compositions |
DE19735959A1 (en) * | 1997-08-19 | 1999-02-25 | Basf Ag | Thermally curable, aqueous binding agent composition |
US5965638A (en) * | 1997-09-08 | 1999-10-12 | Elk Corporation Of Dallas | Structural mat matrix |
CA2634327C (en) * | 1999-06-17 | 2011-04-26 | Borden Chemical, Inc. | Low emission formaldehyde resin and binder for mineral fiber insulation |
MXPA01001665A (en) * | 2000-02-18 | 2002-04-01 | John Michael Friel | PAINTINGS FOR THE MARKING OF ROADS, PREPARED FROM PREPINTURES; METHOD AND APPARATUS FOR FORMING ZONES AND LINES MARKED ON THE ROADS, WITH SUCH PAINTS AND DEVICE FOR APPLYING SUCH PAINTS |
US6642299B2 (en) * | 2000-12-22 | 2003-11-04 | Georgia-Pacific Resins, Inc. | Urea-formaldehyde resin binders containing styrene acrylates and acrylic copolymers |
US7384881B2 (en) * | 2002-08-16 | 2008-06-10 | H.B. Fuller Licensing & Financing, Inc. | Aqueous formaldehyde-free composition and fiberglass insulation including the same |
US20040224594A1 (en) * | 2003-04-18 | 2004-11-11 | Choi Wai Ming | Low density nonwoven glass fiber web |
US20050215153A1 (en) * | 2004-03-23 | 2005-09-29 | Cossement Marc R | Dextrin binder composition for heat resistant non-wovens |
DE102004016646A1 (en) * | 2004-03-31 | 2005-10-27 | Basf Ag | Process for the production of semi-finished products and molded parts |
US20060057919A1 (en) * | 2004-09-10 | 2006-03-16 | Linlin Xing | Fiber mat having improved tensile strength and process for making same |
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2006
- 2006-07-12 US US11/485,197 patent/US20070059508A1/en not_active Abandoned
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2007
- 2007-07-12 WO PCT/US2007/073316 patent/WO2008008868A2/en active Application Filing
- 2007-07-12 CA CA 2659068 patent/CA2659068A1/en not_active Abandoned
- 2007-07-12 MX MX2008015438A patent/MX2008015438A/en unknown
- 2007-07-12 US US12/373,424 patent/US20100120312A1/en not_active Abandoned
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WO2008008868A2 (en) | 2008-01-17 |
US20070059508A1 (en) | 2007-03-15 |
US20100120312A1 (en) | 2010-05-13 |
MX2008015438A (en) | 2008-12-18 |
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Legal Events
Date | Code | Title | Description |
---|---|---|---|
EEER | Examination request | ||
FZDE | Discontinued |
Effective date: 20150226 |